ASEP 218W - Engine Repair and Performance Level 3

1. ENGINE REPAIR
   1. Diagnose and complete general (ASE) Mast level tasks for Engine Repair.
      1. Research vehicle service information such as fluid type, internal combustion engine operation, vehicle service history, service precautions, technical service bulletins, and recalls including xEVs and vehicles equipped with advanced driver assistance systems (ADAS).
      2. Retrieve and record on-board diagnostics, DTCs, monitor status, and freeze frame data; clear codes and data when directed.
      3. Verify operation of the instrument panel engine warning indicators.
      4. Inspect engine assembly for fuel, oil, coolant, and other leaks; determine needed action.
      5. Install engine covers using gaskets, seals, and sealers as required.
      6. Verify engine mechanical timing.
      7. Inspect, remove, and/or replace engine mounts.
      8. Identify service precautions related to service of the internal combustion engine of an xEV.
      9. Remove and reinstall engine on a vehicle equipped with OBDII; reconnect all attaching components and restore the vehicle to running condition.
   2. Diagnose and complete (ASE) Mast level tasks for Cylinder Head and Valve Train.
      1. Identify cylinder head and valve train components and configurations.
      2. Remove cylinder head; inspect gasket condition; install cylinder head and gasket; tighten according to manufacturer's specification and procedure.
      3. Clean and visually inspect a cylinder head for cracks; check gasket surface areas for warpage and surface finish; check passage condition.
      4. Inspect valve actuating mechanisms for wear, bending, cracks, looseness, and blocked oil passages (orifices); determine needed action.
      5. Adjust valves (mechanical or hydraulic lifters)
      6. Inspect and replace camshaft and drive belt/chain; includes checking drive gear wear and backlash, end play, sprocket and chain wear, overhead cam drive sprocket(s), drive belt(s), belt tension, tensioners, camshaft reluctor ring/tone-wheel, and valve timing/variable lift components; verify correct camshaft timing.
      7. Inspect valve springs for squareness and free height comparison; determine needed action.
      8. Replace valve stem seals on an assembled engine; inspect valve spring retainers, locks/keepers, and valve lock/keeper grooves; determine needed action.
      9. Inspect valve guides for wear; check valve stem-to-guide clearance; determine needed action.
      10. Inspect valves and valve seats; determine needed action.
      11. Check valve spring assembled height and valve stem height; determine needed action.
      12. Inspect valve lifters and hydraulic lash adjusters; determine needed action.
      13. Inspect and/or measure camshaft for runout, journal wear and lobe wear.
      14. Inspect camshaft bearing surface for wear, damage, out-of-round, and alignment; determine needed action.
   3. Diagnose and complete (ASE) Mast level tasks for Engine Block Assembly.
      1. Identify engine block assembly components and configurations.
      2. Remove, inspect, and/or replace crankshaft vibration damper (harmonic balancer).
      3. Disassemble engine block; clean and prepare components for inspection and reassembly.
      4. Inspect engine block for visible cracks, passage condition, core and galley plug condition, and surface warpage; determine needed action.
      5. Inspect and measure cylinder walls/sleeves for damage, wear, and ridges; determine needed action.
      6. Perform deglazing and cleaning of cylinder walls.
      7. Inspect and measure camshaft bearings for wear, damage, out-of-round, and alignment; determine needed action.
      8. Inspect crankshaft for straightness, journal damage, keyway damage, thrust flange and sealing surface condition, and visual surface cracks; check oil passage condition; measure end play and journal wear; check crankshaft position sensor reluctor ring (where applicable); determine needed action.
      9. Inspect main and connecting rod bearings for damage and wear; determine needed action.
      10. Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; determine needed action.
      11. Inspect and measure piston skirts and ring lands; determine needed action.
      12. Determine piston-to-bore clearance.
      13. Inspect, measure, and install piston rings.
      14. Inspect auxiliary shaft(s) (balance, intermediate, idler, counterbalance and/or silencer); inspect shaft(s) and support bearings for damage and wear; determine needed action; reinstall and time.
      15. Assemble engine block.
   4. Diagnose and complete (ASE) Mast level tasks for Lubrication and Cooling Systems.
      1. Identify lubrication and cooling system components and configurations.
      2. Perform engine oil and filter change; use proper fluid type per manufacturer specification; reset maintenance reminder as required.
      3. Perform cooling system pressure and dye tests to identify leaks; check coolant condition and level; inspect and test radiator, pressure cap, coolant reservoir/recovery tank, heater core, and galley plugs; determine needed action.
      4. Identify causes of engine overheating
      5. Inspect, replace, and/or adjust drive belts, tensioners, and pulleys, check pulley and belt alignment.
      6. Inspect and test coolant; drain and recover coolant; flush and/or refill cooling system; use proper fluid type per manufacturer specification; bleed air as required.
      7. Identify different types of water/coolant pumps (belt driven, chain driven, and electric).
      8. Remove, inspect, and replace thermostat and gasket/seal.
      9. Inspect, remove, and replace water/coolant pumps.
      10. Remove and replace radiator.
      11. Inspect and test fan(s), fan clutch (electrical and/or mechanical), fan shroud, and air dams/shutters; determine needed action.
      12. Perform oil pressure tests; determine needed action.
      13. Inspect auxiliary coolers; determine needed action.
      14. Inspect, test, and replace oil temperature and pressure switches and sensors.
      15. Inspect oil pump gears or rotors, housing, pressure relief devices, pressure control devices, and pump drive; determine needed action.
2. ENGINE PERFORMANCE
   1. Diagnose and complete general (ASE) Mast level tasks for Engine Performance.
      1. Research vehicle service information such as fluid type, vehicle service history, service precautions, technical service bulletins, and recalls including xEVs and vehicles equipped with advanced driver assistance systems (ADAS).
      2. Retrieve and record on-board diagnostics, DTCs, monitor status, and freeze frame data; clear codes and data when directed.
      3. Verify proper engine cooling system operation; determine needed action.
      4. Verify correct camshaft timing including engines equipped with variable valve timing (VVT) systems; determine needed action.
      5. Verify engine performance concerns; determine needed action.
      6. Diagnose abnormal engine noises or vibration concerns; determine needed action.
      7. Diagnose the cause of excessive oil consumption; coolant consumption, unusual exhaust color, odor, and sound; determine needed action.
      8. Perform engine manifold pressure tests (vacuum/boost); determine needed action.
      9. Perform cylinder power balance test; determine needed action.
      10. Perform cylinder cranking and running compression tests; determine needed action.
      11. Perform cylinder leakage test; determine needed action.
   2. Diagnose and complete (ASE) Mast level tasks for Computerized Controls.
      1. Identify computerized control system components and configurations.
      2. Access and use service information to perform step-by-step (troubleshooting) diagnosis.
      3. Perform active tests of actuators using a scan tool; determine needed action.
      4. Demonstrate knowledge of OBD readiness flags, monitors, and drive cycle for repair verification.
      5. Inspect and test computerized engine control system sensors, powertrain/engine control module (PCM/ECM), actuators, and circuits using a graphing multimeter (GMM), digital storage oscilloscope (DSO), and/or scan tool; determine needed action.
      6. Describe the process for reprogramming or recalibrating the powertrain/engine control module (PCM/ECM).
      7. Diagnose the causes of emissions or driveability concerns with stored or active diagnostic trouble codes (DTC); obtain, graph, and interpret scan tool data.
      8. Diagnose emissions or driveability concerns without stored or active diagnostic trouble codes; determine needed action.
      9. Diagnose driveability and emissions problems resulting from malfunctions of interrelated systems (cruise control, security alarms, suspension controls, traction controls, HVAC, automatic transmissions, non-OEM installed accessories, or similar systems); determine needed action.
   3. Diagnose and complete (ASE) Mast level tasks for Ignition System.
      1. Identify ignition system components and configurations.
      2. Remove and replace spark plugs; inspect secondary ignition components for wear and damage; determine needed action.
      3. Diagnose no-starting, hard starting, engine misfire, poor driveability, spark knock, power loss, poor mileage and emissions concerns related to ignition system problems; determine needed action.
      4. Inspect and test crankshaft and camshaft position sensor(s); determine needed action.
      5. Inspect, test, and/or replace ignition control module and/or powertrain/engine control module; reprogram/initialize as needed.
   4. Diagnose and complete (ASE) Mast level tasks for Fuel, Air Induction, and Exhaust Systems.
      1. Identify fuel, air induction, and exhaust system components and configurations.
      2. Replace fuel filter(s) where applicable.
      3. Inspect, service, or replace air filters, filter housings, and intake duct work.
      4. Inspect integrity of the exhaust manifold, exhaust pipes, muffler(s), catalytic converter(s), resonator(s), tail pipe(s), and heat shields for leaks and unmetered air; determine needed action.
      5. Inspect condition of exhaust system hangers, brackets, clamps, and heat shields; determine needed action.
      6. Check and refill diesel exhaust fluid (DEF).
      7. Check fuel for quality, composition, and contamination; determine needed action.
      8. Inspect and test fuel pump(s) and pump control system for pressure, regulation, and volume; determine needed action.
      9. Inspect throttle body, air induction system, intake manifold and gaskets for vacuum leaks and/or unmetered air.
      10. Inspect, test, and/or replace fuel injectors on low- and high-pressure systems.
      11. Verify proper idle speed; determine needed action.
      12. Perform exhaust system back-pressure test; determine needed action.
      13. Demonstrate knowledge of the operation of turbocharger/supercharger systems.
      14. Diagnose hot or cold no-starting, hard starting, poor driveability, incorrect idle speed, poor idle, flooding, hesitation, surging, engine misfire, power loss, stalling, poor mileage, engine run-on, and emissions problems related to fuel, air induction, and exhaust system problems; determine needed action.
   5. Diagnose and complete (ASE) Mast level tasks for Emissions Control Systems.
      1. Identify emission control system components and configurations.
      2. Inspect, test, service, and/or replace positive crankcase ventilation (PCV) filter/breather, valve, tubes, orifices, and hoses; determine needed action.
      3. Diagnose oil leaks, emissions, and driveability concerns caused by the positive crankcase ventilation (PCV) system; determine needed action.
      4. Diagnose emissions and driveability concerns caused by the exhaust gas recirculation (EGR) system; inspect, test, service and/or replace electrical/electronic sensors, controls, wiring, tubing, exhaust passages, coolers, vacuum/pressure controls, filters, and hoses of exhaust gas recirculation (EGR) systems; determine needed action.
      5. Inspect and test electrical/electronically operated components and circuits of secondary air injection systems; determine needed action.
      6. Diagnose emission and driveability concerns caused by catalytic converter system; determine needed action.
      7. Diagnose emissions and driveability concerns caused by the evaporative emissions control (EVAP) system; determine needed action.